TRAINING

M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

INDEX

INDEX .............................................................................................................................................................. 1

PALTRONIC 50 VERSION 4.2 ........................................................................................................................ 2

1. System description ................................................................................................................................ 2

1.1 Basic concept ......................................................................................................................................... 2
1.2 Digital system ......................................................................................................................................... 3

2. Paltronic 50 operating ............................................................................................................................ 4

2.1 Operating functions ................................................................................................................................ 4
2.2 Emergency cut off function..................................................................................................................... 5
2.3 On/Off button.......................................................................................................................................... 5
2.4 Capacity indicator ................................................................................................................................... 5
2.5 Overload protection system ................................................................................................................... 6
2.6 Logic of locked functions ........................................................................................................................ 7
2.7 Examples for overload situations ........................................................................................................... 8
2.8 HPLS system........................................................................................................................................ 11
2.9 Warning horn function .......................................................................................................................... 11

3. Description of system parts ................................................................................................................ 12

3.1 CAN bus wiring and addressing ........................................................................................................... 12
3.2 Main unit ............................................................................................................................................... 14
3.3 Display unit ........................................................................................................................................... 22
3.4 Spool position box for crane functions (digital inputs 1) ....................................................................... 23
3.5 Spool position box for fly jib (digital inputs 2) ....................................................................................... 25
3.6 Inputs for stabilizer monitoring system ISC (digital inputs 3) ............................................................... 26
3.7 Encoder (angle transducer) .................................................................................................................. 27

4. Load limits and workings areas – version without encoder ............................................................ 28

4.1 Nominal load, HPLS load, negative load limits..................................................................................... 28
4.2 Order option SHB01 ............................................................................................................................. 29
4.3 Order option SHB07 ............................................................................................................................. 30
4.4 Setting of load limits “Slewing 2” .......................................................................................................... 32
4.5 Order option IS001 ............................................................................................................................... 35

5. Load limits and working areas – version with encoder .................................................................... 36

5.1 Available load limits .............................................................................................................................. 36
5.2 Nominal load, HPLS last, negative load limits ...................................................................................... 37
5.3 Load limit slewing 1 .............................................................................................................................. 37
5.4 Integrated Stability Control System ISC ............................................................................................... 38
5.5 High stand limitation system IS001, IS002 ........................................................................................... 42
5.6 Execution EN 280................................................................................................................................. 43

6. Paltronic 50 special functions ............................................................................................................. 44

6.1 Active oscillation suppression system AOS ......................................................................................... 44
6.2 Boom angle monitoring system (STEIL1, STEIL2) .............................................................................. 45
6.3 Dual power system DPS, DPS plus ..................................................................................................... 47

7. Load limits with Fly-Jib ........................................................................................................................ 49

7.1 Available load limits .............................................................................................................................. 49
7.2 Logic of load limits ................................................................................................................................ 49

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

Paltronic 50 Version 4.2

1. System description
This description is in principle valid for the Paltronic 50 system, version 4.2
Further on this description is also valid for the versions 4.4 and 4.6

The version 4.2 is able to replace any previous version of Paltronic 50; the main board of
version 4.2 also for the first time got a new hardware.

History of Paltronic 50 serial versions:

 P50 V 2.4 first serial version to replace OFB electric overload system
 P50 V 2.6 allows electronic HPLS
 P50 V 2.8 allows all functions of version 2.6 + AOS (active oscillation suppression)
 P50 V 3.0 like 2.8 plus „lever comparison“ between RRC signal and spool position
 P50 V 4.0 like 3.0, with encoder and ISC-System (stabilizer monitoring)
 P50 V 4.2 includes all previous versions, further DPS plus; new hardware
 P50 V 4.4 Software update of version 4.2
 P50 V 4.6 Software update of version 4.4

1.1 Basic concept

The Paltronic 50 version 4.2 is a CE-conform, electronic crane control system with integrated data bus,
which is able to control all possible comfort and safety systems on the crane.

The system is available in two basic versions, with or without encoder (angle transducer) to monitor
the slewing position of the crane. The version depends on the order options of the crane.

Some order options require an encoder in any case, but generally it depends on the order specification
if the crane comes with or without encoder.

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1.2 Digital system

Depending on order options, the P50 CAN bus system consists of different components, mounted in
one or more electric boxes on the crane.

CAN bus participants (maximum)

M Main board, with digital status

code display
61 51 Digital inputs for the spool position
monitoring of the crane functions
(digital address 51)
52 Digital inputs for the spool position
monitoring of the fly jib functions
62 63 (digital address 52)
53 Digital inputs for the monitoring of
64 65 the ISC switches (stabilizer
position, digital address 53)
62-65 Operating terminal, mounted on
the crane (max 4 possible, digital
address between 62 and 65)

M 61 LED feed back system on the

EB-2440
RRC transmitter (digital address
61).
ADD 7F Encoder to sense the slewing
51 position of the crane column
(digital address 7F)
ADD Additional electronic board for
further digital inputs to allow
options like SHB07 or IS001 and
more
AOS
AOS Control board for the AOS
system, mounted on the board
with address 51(optional)
52
Minimum versions
P50 V4.2 standard
 M, 51, 62
P50 V4.2 with encoder
53  M, 51, EN, RC

7F

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
2. Paltronic 50 operating
The Paltronic 50 system can be either controlled via the operating terminal on the crane or an RRC
transmitter with feed back system.

2.1 Operating functions

The P50 terminal has never been changed since the first version on the market.
On RRC transmitters with feed back functions, the position of the various P50 function button depends
on the design of the transmitter. Therefore check the operating manual of the RRC system.
The function is the same on the transmitter and the terminal.

Terminal of P50 (all versions)

Legend

1 .. Emergency cut off button

2... Load capacity indicator 60-100%
3... On-Off switch
4... Overload protection system
5... HPLS - system

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2.2 Emergency cut off function

If one of the emergency stop buttons on the crane is pressed, the

crane dump valve loses power and the crane cannot be operated
anymore.
This is valid for all different kinds of emergency cut off systems.

To allow a restart of the crane operating, all buttons have to be

released into neutral position again.

2.3 On/Off button

Paltronic 50 should be connected to the PTO switch of the truck. This means, that Paltronic only
should have power, if the PTO is on. A direct connection to the ignition key or the battery is not
allowed.
When connected so, the P50 starts up automatically when starting the PTO.
It is therefore no t necessary to press the On/Off button. Anyway the On/Off button can be pressed to
deactivate and later reactive the system manually.
The Code 98.00 shows the deactivate situation, crane movements are not possible during this time.
The Paltronic hour meter does not count in this condition.

The LED on the ON-OFF-button (green)

 Is on, if the system is switched on and operating
 Is off, if the system is switched off
 flashes, if the system is switched on but the emergency cut off button is locked
(for example when trying to extend the extension booms in overload situation)

2.4 Capacity indicator

The capacity indicator informs the operator about the actual load capacity on the crane of fly jib in 10%
steps as soon as the value is above 60%.

LED for 60, 70 and 80% - green

LED for 90% - yellow
LED for 100% - red

Logic of the capacity indicator

 The indicator always shows the value of the currently active limit (HPLS, SHB01 …)
 Compares the crane and the fly jib signal and shows the higher value
 At 90%, the intermitting alarm starts (press OLP to confirm and switch off the horn)
 At 100% the indicator starts to flash and the permanent alarm starts to sound
 The indicator also starts to flash, when another system on the crane is in overload (like rope
winch)

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

2.5 Overload protection system

The overload protection system on Paltronic 50 is realized with the emergency cut-off valve.
Different signals for an overload situation can be given to Paltronic from:
 Pressure transducers on main boom or fly jib cylinders (always two per cylinder)
 Switches for manual extensions, rope winch, workman basket and so on

If an overload situation occurs and the operator moves a not allowed function (depending on the
overload situation and the crane position, all load moment increasing functions are not allowed), the
dump valve drops and the crane cannot be operated.
If the movement is an allowed one, it is also possible in overload situation.
Additionally, the Paltronic 50 display shows the reason for the overload on the display unit.

Four diodes are showing

overload on:

 Reduced load limits (1)

 Overload on Fly-Jib (2)
 Overload on crane (3)
 Overload on rope winch (4)

Overload due to a peak pressure shock (false overload)

If the overload system acts because of a peak pressure in the main lift cylinder
or the fly jib cylinder (in case, the crane is not really in overload), the peak
pressure can be released by pressing the OLP button and lowering the crane
(all functions are possible except extensions out).
The operator has 1.5 s to release the system, beginning with acting the lever.
After using this function once, it is locked for 30 seconds to prevent the customer operating the crane
in real overload conditions.
The system is also locked during the first 30 seconds after start up.

The LED on the OLP button (green)

 Is off in normal working condition
 Is on, after pressing the button in overload condition (until a movement is activated)
 Flashes during the 30 seconds while the crane is locked

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2.6 Logic of locked functions

If an overload situation occurs, different functions are not allowed anymore. This depends on the crane
capacity rate, on the boom position and on the system causing the overload situation. Also a critical
situation (error in the data bus) can be the reason to lock functions.

2.6-1 Reasons for locked functions

A) Reaching adjusted limits

 Crane or fly jib reaches it’s adjusted limit
 Reduced limits (SHB, ISC limits, other derated areas) to protect the vehicle (stability)
 Switches to protect equipment (rope winch, manual extensions)
 Protected operating areas (IS001 high stand limitation, roof protection systems)

B) System error
 Data bus input errors, missing or wrong signals, bad data diagram
 Broken sensor wire
 Data bus error (bad data diagram)
 Logic error (e.g. lever monitoring system between RRC and control valve)
 If these errors occur, the customer has to override the crane safety system and to visit a
workshop.

If applicable or necessary, Paltronic locks functions, that

 increase the load moment
 worsen the truck stability (including slewing movements)
 are not completely known through the spool monitoring

A full explanation is not given of the Paltronic 50 logic as this depends a lot on the crane equipment.

2.6-2 Status code

In any case, the status code delivers useful information about the reason of an error or overload
situation. See therefore the code description at the end of this document or the error documentation of
Paldiag.NET software.

2.6-3 Hydraulic limitation

The highest load limit on the crane is protected via the main relief valve of the system.
Therefore the lifting of the load is not possible in this situation anymore.
Additionally port relief valves are used to limit the operating pressure of specified functions.

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2.7 Examples for overload situations

The following examples should explain the logic of Paltronic; a complete explanation is impossible due
to the complexity of the system.

2.7-1 Overload on crane

Legend

Red arrow locked function

White arrow free function
Pink arrow only locked, if crane is not in highest working area
Black arrow locked, if the actual load limit is overridden by 20 bar
P1, P2 level indicator on crane of fly jib

P2
P1

P1
P2

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
2.7-2 Overload on fly jib

Legend

Red arrow locked function

White arrow free function
Pink arrow only locked, if crane is not in highest working area
Black arrow locked, if the actual load limit is overridden by 20 bar
P1, P2 level indicator on crane of fly jib

P2
P2

P2

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
2.7-3 Overload on Winch

Legend

Red arrow locked function

White arrow free function

a) Winch mounted on main boom

b) Winch mounted on outer boom

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
2.8 HPLS system

The Palfinger HPLS system (High Power Lifting System) allows an additional increase of the lifting
moment by a certain percentage at a reduction of the speed at the same time.
Palfinger uses different versions of HPLS systems
 Hydraulic HPLS
At the hydraulic HPLS system, the lifting power is controlled by an additional hydraulic valve
and the speed is reduced by a flow divider.
This system is used only in special cases.

 Electronic HPLS (used on all cranes with the “EH” control system)
At the electronic HPLS system, the lifting power is controlled by Paltronic 50 and the required
reduction of speed is done by the RRC system.
The “EH” control system requires the following systems:
o Paltronic 50
o Scanreco P2 or Hetronic BMS2 radio remote control

 Automatic HPLS (“SH“ control system) is not available in combination with Paltronic 50

HPLS is not installed on all models and can also not be ordered as a retrofit kit, because it changes
the crane nomination.
As soon as the operator switches on the system, the crane lifting capacity is increased to the HPLS
limit.
At the same time, the operating speed of each function is reduced to a programmable, individual
speed by reducing the RRC output signal.
The HPLS system can only be used in RRC mode.

HPLS-LED
 is off, if the system is switched off
 is on, if HPLS is switched on and necessary
 Is flashing, if HPLS is on but not necessary (crane is not in”HPLS area“).

2.9 Warning horn function

Each Paltronic 50 system is equipped with the warning horn function.

When pressing the OLP button for more than 0.5 seconds, the horn starts to give a signal, if it has
been installed on the crane.
This function is a part of the EN12999 standard (order code), or is standard anyway if the crane has
 a RRC system installed
 more than 12 m outreach
The horn is wired to the digital output channel H6 of the P50 main board.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

3. Description of system parts

The following description describes all parts of the P50 system.
Depending on the crane equipment, not all parts are necessary at all cases.

3.1 CAN bus wiring and addressing

3.1-1 CAN-Bus

CAN-Bus stands for “controller area network”.

A CAN bus system is a digital network, where data are sent in binary code form between the
components.
Paltronic 50 works with the CAN-kingdom language.

3.1-2 CAN bus cable

All CAN bus participants are wired together with the so called CAN bus cable.
Each CAN participant gets an address and is therefore able to receive and transmit data. The address
system allows a free wiring of the system, each free CAN bus plug can be used for each participant.
The CAN bus cable used in P50 systems consists of 7 wires:

1 CA CAN bus signal A

2 CB CAN bus signal B
3 C- CAN bus ground (-)
4 + power supply (+) if emergency loop is closed
5 - Power supply (-)
6 e.c.o. Emergency cut off loop
7 e.c.o. Emergency cut off loop
8 (+) not used

If the emergency loop is closed, the green diode nearest the plug is on.
Important
 If a CAN bus plug is not used in the system, the emergency cut off loop has to be closed by a
jumper (between pin 6 and 7), otherwise the system will not operate.

3.1-3 CAN bus addressing

Paltronic 50 works with the CAN bus system called”CAN kingdom“.

With this technology a master unit (without adjustable address) controls all other participants, which
have an address consisting of a two digit number.
To ensure a trouble free operation, the following rules must be followed:
General
 An address can only be used once
 The second digit on the address cannot be zero

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First digit
 The first digit is given in the system by the kind of the participant and cannot be changed
 It is a five for all digital spool position boxes (digital input boxes)
 It is a six for all display units including the RRC system
 It is a seven for the encoders

Second digit
The second digit is adjustable by a switch on the board (display and input units) or programmable
by wiring or coding on the others. The setting is possible from 0 to F.

The arrow shows the current setting of the second digit.

An adjustment must not be done while the system is switched on.

The following rules are important:

 The address of the spool position box for crane functions must be 51.
 The address of the spool position box for fly jib functions must be 52.
 The address of the stabilizer monitor box (ISC) must be 53.
 The address of the RRC receiver (in combination with LED feedback) must be 61.
 The address of the encoder must be 7F.
 The addresses of the display units must be 62, 63, 64 or 65.

3.1-4 CAN bus logic

If the system recognizes a new CAN participant during start up, it will be registered.
If an already registered CAN participant is missing during start up, the system shows an error code.
If a normal display unit does not work, the system shows a code but the crane can be operated (67.xx
or 68.xx).
If any other participants fail, the CAN bus shows an error code and switches to emergency stop.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.2 Main unit

The main board has been redesigned for the version 4.2. A visible difference between the version 4.2
and all previous versions is the plug for the computer connection, which has got 5 pins now instead of
the previous version with 3 pins.

3.2-1 General wiring

The main unit is equipped with various inputs and outputs, which are put together in 8 different plugs.
The following guidelines are important:
+ This sign signifies, that a positive voltage can be taken here to feed a switch
- This sign signifies, that a negative voltage can be taken here to feed a switch
s This sign signifies a signal in- or output

Plug grouping
1 PC – connection to communicate with the Paldiag Software
2 Digital inputs from the crane
3 Analogue inputs from the crane
4 Digital outputs to control the emergency cut off system
5 Digital outputs for the crane
6 Power supply
7 Fuse 5 A
8 CAN bus plug with control LED

Shown in pink color: Additional optional board for digital inputs

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3.2-2 Power supply

The Paltronic 50 system operates correctly with a feed voltage between 11V-32V DC on the UDC-
plug (6). This means the Paltronic is the same for 12V and 24V system.

The green LED on the plug (6) is on if the power supply is ok. It is
not on, if the fuse is blown.
Please observe the correct wiring of (+) and (-). The system is
protected with a 5 A fuse (7).

3.2-3 CAN bus plug

The main board has three connections for CAN bus plugs
(8).
Each plug has a control diode to show a correctly closed
and connected emergency cut off loop.
If this loop is closed, all other internal parts are supplied
with feed voltage through the CAN bus wire.

3.2-4 RS 232 connection

The RS232 connection allows the communication with the

Paldiag.NET software.
The plug is wired internally to a 16 pin Amphenol plug on
the junction box. The connection has now (version 4.2) 5
pins instead of 3 to be able to flash the programs.
Wiring
T Transmit (signal to computer)
R Receive (signal from computer)
-G Ground
RTS Ready to send
CTS Clear to send

3.2-5 Diagnostic cable

The connection cable to the computer has a 9-pin RS232 plug on one side (serial port) and a round
Amphenol plug on the other side (C 16-3), which has to be connected to the main unit.
This cable is available at Palfinger with the spare part number EEA1945.
Computers with USB connection can be used as well, therefore an USB-serial port adapter is
necessary (to be installed and set up properly in the computer).

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.2-6 Digital inputs

The main unit has 8 digital inputs, which are predefined for the most important signals from the
crane.
The (+) and (-) pins can be used to supply electric power to the connected switches; the (s)
connection carries the signal. The red LED is on if the input gets a signal.

Legend
2a ..... Input for external OLP button (S2)
The red LED is on while the button is pressed.

2b ..... Input from the key switch for Manual/Automatic mode

The red LED is on in automatic (RRC) mode.

2c ..... Input from external HPLS On/Off button.

The red LED is on while pressing the HPLS On/Off button.

2d ..... At version without encoder

Input from switch for SHB system ”slewing left“ (B13)
The red LED is on when the switch is not on the bracket (outside SHB area).

2e ..... At version without encoder

Input from switch for SHB system ”slewing right“ (B14)
The red LED is on when the switch is not on the bracket (outside SHB area).

2d ..... At version with encoder

Input for slewing angle check (B205)
The red LED is on when the switch is not on the bracket.

2e ..... At version with encoder

Input for crane mode active (switch crane/stabilizer S33).
The red LED is on in stabilizer mode.

2f ..... Input for rope winch overload switch (B4)

The red LED is on if winch is not in overload.

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On the inlets 2g and 2h a different system is used which is able to indicate broken connections.
Therefore the system “broken wire indication” for outer boom (2g) and fly jib (2h) has to be activated
with Paldiag.NET. Additionally, the correct switches are necessary (with version 4.0 this is a standard
feature).
2g ..... Level indicator for crane outer boom (B1)
The red diode is on as long as the boom is below horizontal level.
The green diode is on as long as the cable connection in ok.
If the system to indicate wire breaks is switched off, both diodes act together.

2h ..... Level indicator for fly jib (B301)

The red diode is on as long as the boom is below horizontal level.
The green diode is on as long as the cable connection in ok.
If the system to indicate wire breaks is switched off, both diodes act together.

3.2-7 Analogue inputs

The analogue inputs of Paltronic 50 are reserved for the pressure transducers of the main lifting and
the fly jib cylinder.

Wiring

3a ..... Pressure transducer crane piston side

3b ..... Pressure transducer crane piston rod side

3c ..... Pressure transducer fly jib piston side

3d ..... Pressure transducer fly jib piston rod side

The transducer signal must be between 1.25 and 19.7 mA, otherwise Paltronic states an error code
(either broken wire or short cut in the system).
Each Paltronic system is generally prepared for fly jib but this option must be activated with the
Paldiag.NET software.
If the fly jib is removed, the connections have to be plugged to a blind plug on the crane extension
boom system. This blind plug carries an electrical resistance and sends a signal of 2.75 mA which
states, that the fly jib is not installed.

Attention
 The version 4.2 of Paltronic 50 is preset for 600 bar (8702 psi) pressure transducers. If for any
reasons 400 bar (5802 psi) transducers are used, the programming has to be modified.
 The (-) connection must not be connected when using the 24V 600 bar (8702 psi) transducers.
This would cause an error code (11.00 to 14.00).
 Also refer to the service information 003/2004 in the Palfinger Extranet.

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3.2-8 Emergency cut off connections

The control of the emergency cut off valve is based on a certain logic, which depends on the signals of
the inputs 4a and 4b.

4a ..... Input of the dump valve signal from the RRC system.
If the crane has no RRC system, a jumper between (+) and (s) is necessary.

4b ..... Emergency cut off control of HPLS outputs Y81 and Y82.
 Option: Jumper between HPLS and Y0; in this case both signals drop with
the dump valve.
 Standard: Jumper between HPLS and +; in this case both outputs stay
Independent of the dump valve signal (for hydraulic LS-HPLS).

4c ..... Control signal for emergency cut off valve.

The red diode is on, if the output carries a signal.

3.2-9 Digital outputs

These outputs are necessary to control different valves on the crane.

5a ..... Output warning horn H6

This is used for the additional warning horn (OLP-button 0.5 s pressed).
The output carries signal as long as the horn sounds.

5b ..... Signal for return oil utilization (Y190) on the LHV of the extension boom system.
Controls the magnetic valve for the return oil utilization system.
The function is normally operated from the RRC system or an external switch.
The output carries signal as long as the magnetic valve has power (system on).

5c..... Signal for overload horn H5

This signal controls the horn of the overload protection system.
The output carries signal as long as the horn sounds.

5d ..... HPLS output Y82

Y82 is only used together with certain hydraulic HPLS valves.
The output carries signal as long as HPLS is on.

5e ..... HPLS output Y81

This output controls the HPLS speed of the crane (mostly RRC system).
The output carries signal as long as HPLS is off.

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3.2-10 Status display

The Paltronic 50 system is equipped with a status display, which shows permanently the current
operating status of the system.

During start up, the system first controls the LED display (88.), after this it shows the installed version
of the Paltronic 50 software.

Example: During start up, the display first shows 88.

After this, the display shows “4.2”.
This shows that the P50 system is programmed with Version 4.2.

After this, the system shows the current error code.

The codes are shown either as a fixed number or as two flashing numbers; therefore see the code
description at the end of this document.
All codes are permanently stored in an error memory, which can be viewed with the Paldiag.NET
software.

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3.2-11 How to read out the error memory without computer

 To enter this read out mode, first press the emergency stop button on the display. Then restart
the system while holding the On/Off button .
 The display starts to flash quickly and shows the first code of the memory.
Example: The code shows 02 and 63. While flashing.
This means that the code 63.02 is stored as the latest error which occurred.
It is not possible to find out, how often the code occurred.

 The code with the “dot” is always the main code, the code without the “dot” is the additional info.
 By pressing the OLP button the next code can be shown.
 This can be done continuously until the first code shows up the third time.
 To reset to normal mode, restart the system again.

3.2-12 Boot mode

Paltronic 50 Software Version 4.2 contains boot software, which allows a so called Flash-Update of the
unit.

It is therefore possible to upgrade the 4.2 version to a higher version (e.g. 4.4) later on.

Paltronic 50 V4.2 automatically switches to boot mode for 5s, when the system gets restarted while
Paldiag.NET is connected and logged on.

During these 5s, the display shows bt.

If no update gets started within these 5s, P50 switches back via the normal start up sequence (88. 
4.2  00.) into user mode.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.2-13 Additional board

The additional board EEA-2937 can be connected to the prepared 10-pin plug (S) on the main board
and opens the possibility to control 6 additional digital inputs.
The board is only fitted when the order options require it.

1 2 3 4 5
1

S 2

5 6

The wiring of the inputs is different with versions with or without encoder. The logic of all inputs is
explained in chapter 4.

A) Version without encoder

1 ..... Switch for high stand limitation “slewing left” active.
The diode is on when the switch is not activated (switch not on bracket).
2 ..... Switch for high stand limitation “slewing right” active.
The diode is on when the switch is not activated (switch not on bracket).
3 ..... Switch for “high stand platform active”
The diode is on as long as the crane is operated from the high stand platform.
4 ..... Switch for SHBUB active, if crane is in SHB area.
Switch between load limit 1/2 of the slewing 2 area, when crane is outside SHB area
If the diode is on, the always higher load limit is active.
5 ..... Switch between load limit 1/2 of the SHB area.
Switch for slewing 2 active, if crane is outside the SHB area.
If the diode is on, the always higher load limit is active.
6 ..... Signal “manual extension” or “boom angle monitoring” system (STEIL1, STEIL2).
The diode is on as long as the system is not in overload or the boom is not in high position.

B) Version with encoder

1 ..... Input ”workman basket“
The diode is on in normal working mode.
2 ..... Switch for second high stand active.
The diode is on as long as the crane is not operated from the high stand platform.
3 ..... Switch for first high stand active.
The diode is on as long as the crane is not operated from the high stand platform.
4,5,6 .. Same as version without encoder, but slewing 2 is not available.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.3 Display unit

3.3-1 Operating

See chapter 2.

3.3-2 Wiring

Each unit has 2 CAN bus plugs and as well as a plug for the emergency cut off button.
The addressing must be between 62 and 65. The switch to change the address is behind the metal
cover.

Legend

1 Emergency cut off button (to be operated from outside)

2 Plug for the emergency cut off button (included in the emergency loop).
3 CAN bus plug with green diode for the emergency loop
4 CAN bus plug with green diode for the emergency loop

The button has to be connected to the plug otherwise the system does not work due to the open
emergency loop.

3.3-3 RRC feed back terminal (LED)

RRC systems with integrated feed back system generally work similar to the normal display units.
The CAN bus wiring has to be done from a CAN bus plug into the receiver (see description of RRC
systems).
The address of the RRC feed back system is always programmed to 61.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

3.4 Spool position box for crane functions (digital inputs 1)

3.4-1 Purpose

This box is necessary to feel the position of the control valve spools of the crane elements during
operating.
The address must be 51.
The wiring is predefined and cannot be changed.

3.4-2 Wiring

1 Green control diode for emergency cut off loop ok on plug (8)
2 Green control diode for emergency cut off loop ok on plug (9)
3 Green control diode for internal power supply ok
4 Connection for control valve function “slewing to the left“
5 Connection for control valve function „“slewing to the right“
6 Connection for control valve function “extend extension booms“
7 Connection for control valve function “rope winch lifting“
8 CAN bus plug
9 CAN bus plug
10 Connection for control valve function “lowering outer boom“
11 Connection for control valve function “lifting outer boom“
12 Connection for control valve function “lifting main boom”
13 Connection for control valve function “lowering main boom”

In case of AOS version only:

14 AOS additional board, input signal for ”manual AOS“
15 AOS additional board, main boom control signal

For AOS also see the description in chapter 6.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.4-3 Function of spool position sensors

To be able to monitor the spool positions, the control valve must be equipped with a spool position
sensor. These sensors are normally part of the control module or must be mounted onto the working
element.
Examples

Nordhydraulik Danfoss
LE 12 manual controlled PVEH-DI

Element, where both directions have to be observed

If both directions have to be monitored on a certain movement (e.g.

slewing left/right), a cable with 4 wires has to be used to connect
the spool position sensor with the control box.

The (+) and the (-) connection feed power to the sensor (S1), the
other two wires (s) carry the control signal.

Colors from left: Brown, green, yellow, white

Element, where one direction has to be observed

If only one direction has to be monitored (like on the rope winch function),
the second (s) signal is not used on the sensor (S1).

The second switch (S2) can be used for another movement of the crane.
The wiring is similar.

Colors from left: Brown, green, yellow, white

Function of the control diodes

 If the spool is in neutral position, the module on the control valve sends a signal to the spool
position box.
 The signal drops as soon as the function is operated (spool out of neutral position).

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TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.5 Spool position box for fly jib (digital inputs 2)

3.5-1 Purpose

This box is necessary to feel the position of the control valve spools of the fly jib functions during
operating as well as to sense other crane status signals.
The address must be 52.
The wiring is predefined and cannot be changed.

3.5-2 Wiring

1 Green control diode for emergency cut off loop ok on plug (8)
2 Green control diode for emergency cut off loop ok on plug (9)
3 Green control diode for internal power supply ok

4 Connection for control valve function ”counter weight retracting“ or another element
5 Connection for control valve function ”counter weight extending“ or another element

6 Input for emergency cut off feed back signal ”crane mode“
7 Input for emergency cut off feed back signal ”stabilizer mode“

8 CAN bus plug

9 CAN bus plug

10 Input for switch B238 “reduced load limit on fly jib“ (DPS)
11 Connection for control valve function ”fly jib extension booms extending“
12 Connection for control valve function ”fly jib lowering“
13 Connection for control valve function ”fly jib lifting“

The logic for the different signals is written under chapter 5 (ISC).

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.6 Inputs for stabilizer monitoring system ISC (digital inputs 3)

3.6-1 Purpose

This box is necessary to feel the outrigger and stabilizer positions, if the crane is equipped with the
ISC stabilizer monitoring system.
The address must be 53.
The wiring is predefined and cannot be changed.

3.6-2 Wiring

1 Green control diode for emergency cut off loop ok on plug (8)
2 Green control diode for emergency cut off loop ok on plug (9)
3 Green control diode for internal power supply ok

4 Input for “crane stabilizers down on right side “

5 Input for ”additional stabilizers down on right side“
6 Input for ”right outriggers half extended“
7 Input for “right outriggers completely extended “

8 CAN bus plug

9 CAN bus plug

10 Input for ”left outriggers completely extended“

11 Input for ”left outriggers half extended“
12 Input for “additional stabilizers down on left side“
13 Input for “stabilizers down on left side“

At all inputs the control diode lights up if the condition is true.

The description of the logic is written under chapter 5.
If the crane has no addition stabilizers, a jumper must be used between the front and the rear
stabilizer signal per truck side (e.g. between input 4 and 5).

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
3.7 Encoder (angle transducer)

3.7-1 Purpose

The encoder (U205) is used to permanently feel the slewing position of the crane column. This part
replaces all switches, which are used to feel a defined crane slewing position.
With the help of the Paldiag.NET software, the angle values of the crane load limits can be
programmed.

3.7-2 Wiring

All encoders have to be connected the same way to the Paltronic data bus plug (pin 1 to pin 5 for
“connection”). A jumper is used to close the emergency cut off loop.
The wires under “addressing“ are used to define the address of the encoder. Normally they are not
connected at all which defines the address 7F as a standard for the encoder address.
The pink cable has always to be connected to minus.

Connection YE
YE yellow - CanA - (data bus pin 1)
GR
GR green - CanB - (data bus pin 2)
BK black - Can- - (data bus pin 3) BK
RD red - plus - (data bus pin 4)
BL blue - minus - (data bus pin 5) RD

Addressing BL
WH
WH white - address bit 0
BR brown - address bit 1 BR
GY grey - address bit 2
GY
VL purple - address bit 3
PN pink - address bit minus VL
PN

3.7-3 Slew angle check

To check the plausibility of the encoder signal, a digital switch (B205) is mounted on the column. This
input has to be connected to the main unit under “digital inputs“ (see chapter 3.2-6).
After setting the switch with the Paldiag.NET software (the software programs 4 encoder positions),
the following conditions must be true to allow working:

S
 The switch S (B205) has to be operated between the defined
encoder position A and B (input carries no signal).
 The switch S (B205) can be operated between the defined encoder
position C-A and B-D. A B
C D
 The switch S (B205) must not be operated between D and C (here a
signal is necessary).

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4. Load limits and workings areas – version without encoder
Paltronic 4.2 without encoder works similar to the former version 3.0.
At the version without encoder, the load limits are switched
on and off via inputs, which are activated by roller switches.
P50 V4.0 without encoder integrates nominal and HPLS
load limit as well as the both limits of the slewing 1 system.
SW1-2
SW1-1

SW1-2
SW1-1

General logic rules of P50 load limits

 If more then one load limit is active at the same time,
the lower value is used in Paltronic to switch off.
 In this case, the system locks all movements witch
increase the lifting moment or decrease the stability.
Nominal


HPLS
Paltronic shows an error code to indicate the reason for
the overload situation.

4.1 Nominal load, HPLS load, negative load limits

Each system at least is equipped with a nominal load limit, which defines the standard overload
protection system.
HPLS models additionally have a second limit to allow the HPLS mode, which is normally 10 %
higher than the nominal load limit.
These two limits are pre adjusted from the factory and define the maximum working condition for the
crane.

1 2 1

Legend
1 ..... Nominal load limit of the crane, it is always active if no other limit is active.
Overload status code: 03.02
2 ..... Crane HPLS load limit; active, if HPLS is switched on and no de-rating system is valid.
Overload status code: 03.01

Negative load limit crane

The negative load limit allows limiting the lowering force of the crane to an adjustable value.
P50 switches to overload as soon as the adjusted value is reached (if system is activated).
This helps to avoid “pressing” of the load: 03.05.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.2 Order option SHB01

With the order option SHB01 (slew angle depending lifting capacity regulation), Paltronic receives an
additional load limit, which decreases the lifting capacity in a defined slewing angle. The area has to
be defined by using a bracket on the column.
No additional electronic boards are necessary for this system.

Legend
3 ..... Load limits SHB01, active, if the crane is within the area of the bracket on the column.
Overload status code: 03.09
Factory setting for delivery is 60% of nominal load.
The factory definition for the reduced slewing angle depends on the type, but is mostly 180°
The used load limit in Paltronic is ”slewing 1, load limit 1“.

Logic
 The angles are defined by using two roller switches B13 and B14 on the bracket (input 2d
and 2e, see chapter 3.2-6), which have to be wired into the main board. The additional board
is not necessary for this system.
 The setting has to be defined from the installer after the installation on the truck, it is
therefore necessary to make a load test.
 The correct derated slewing angle can be set by cutting the bracket on the column.
 In case of overload, Paltronic limits all load moment increasing movement as well as the
slewing direction, which would go into the derated area.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.3 Order option SHB07

With the order option SHB07, Paltronic 50 V4.2 is equipped with the additional board and two
additional switches.
One switch is called “SHBUB”, the other one “SHB05”. They are marked with stickers.
With this system, the settings for SHBUB, SHB05 and SHB07 are possible.
Depending on the requirements, one of these options has to be selected with Paldiag.NET and the
necessary wiring has to be made.

2
1
3 3
3 4 4
2 2
1 1

SHBUB SHB05 SHB07

4.3-1 Logic of the system

When delivering the crane, SHB07 comes completely wired with both switches. The input 4 is wired
to the switch SHB05, the input 5 is wired to the switch SHBUB.
The installation company has to select the necessary SHB option and (if applicable) can remove a
not required switch.

General logic
 Only those limits are active, which are selected with
Paldiag.NET.
 Input 4 (SHBUB) activates and deactivates the SHB
limits completely.
 Input 5 (SHB05) switches between the higher and
the lower SHB limit.
 In both cases, a positive signal on the input
activates the higher load limits.

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TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.3-2 Selection SHBUB

When selecting the option SHBUB with Paldiag.NET, the following system is valid:
 As long as the signal input 4 does not carry a signal, SHB is active. If the input has power, the
crane is back to normal working mode.
 The delivered wire with the sticker “SHB05“ is not necessary in this case and can be removed.
 The overload code in SHB is 03.09, the used load limit is ”slewing 1, load limit 1“.
A good example for SHBUB is a truck with a semi trailer, which has a reduced load limit over cabin
without trailer and full capacity with trailer.

4.3-3 Selection SHB05

When selecting the option SHB05 with Paldiag.NET, the following system is valid:
 As long as the input 5 carries a signal, the higher limit of the two SHB limits is active. As soon
as the signal drops, the lower limit is the active one.
 The delivered cable with the sticker “SHBUB” is not necessary with this option a can be
removed.
 The overload status code of the higher SHB limit is 03.09 (slewing 1, load limit 1).
 The overload status code of the lower SHB limit is 03.10 (slewing 1, load limit 2).

A good example for SHB05 is a truck with a semi trailer, which has a dramatically reduced load limit
over cabin without trailer and a higher, but still reduced limit with trailer.

4.3-4 Selection SHB07

When selecting the option SHB07 with Paldiag.NET, a combination of SHBUB and SHB05 is
programmed
 As long as input 4 has no power, one of the SHB limits is active. If input 4 has a signal, the
crane is in SHBUB mode and therefore in normal operating mode (nominal or HPLS limit).
 As long as the input 5 carries a signal, the higher limit of the two SHB limits is active. As soon
as the signal drops, the lower limit is the active one (both conditions only, if input 5 has no
signal).
 Both signal wires are necessary for SHB07.
 The overload status code of the higher SHB limit is 03.09 (slewing 1, load limit 1).
 The overload status code of the lower SHB limit is 03.10 (slewing 1, load limit 2).

The explanation shows, that SHB07 depends on two different signals. A crane with counter weight
and front stabilizers or with counter weight and semi trailer switch could be mentioned.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.4 Setting of load limits “Slewing 2”

With the two load limits of slewing 2 it is possible to reduce the crane lifting capacity to adjustable
values, depending on signal switches.
At a maximum two reduced load limits are available.

4.4-1 Using Slewing 2 (one or both limits) without SHB

Slewing 2 is mostly used for completely reduced working areas. The use of the additional board
offers the therefore necessary inputs for the signal switches.

2 1 2
5 1

Available load limits

1) Nominal
2) HPLS
5) Slewing 2 load limit 2 (lower limit)
6) Slewing 2 load limit 1 (higher limit)

Digital inputs

 Input 5 activates/deactivates slewing 2.If the input

has power, slewing 2 is not active.

 Input 4 switches between the two load limits. It is

only necessary to use this input, if both limits are
required.

o If input 4 has power, the load limit 1 of

slewing 2 is active (higher value).

o If input 4 has no power, the load limit 2 of

slewing 2 is active (lower value).

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.4-2 Combination of 1 load limit of slewing 2 with SHB

This is necessary if a crane with a completely reduced load limit requires a SHB05 system (two
reduced load limits in SHB area).
Therefore the additional board of Paltronic 50 is necessary.

“Slewing 1”, load limit 1 (3) is active, if:

 Switch B13 and/or B14 are on the bracket (no signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 gets a signal (12/24V)

“Slewing 1”, load limit 2 (4) is active, if:

 Switch B13 and/or B14 are on the bracket (no signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 gets no signal (0V) (input 4 as well not (0V))
 The value of limit 4 has to be lower than the value of limit 5, otherwise limit 5 is valid!!

“Slewing 2”, load limit 2 (5) is active, if:

 Switch B13 and/or B14 are not on the bracket (have signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 gets no signal (0V) (input 4 as well not)

3
4
2

1 5

Setting
1 Nominal load =
2 HPLS =
3 Slewing 1, LL 1 =
4 Slewing 1, LL 2 =
5 Slewing 2, LL 2 =
6 Slewing 2, LL 1 =
value nominal load
value HPLS (if installed)
higher value SHB
lower value SHB (lower than load limit 5)
value reduced working area
not relevant, but input 5 has to have no signal

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.4-3 Combination of 2 slewing 2 load limits with SHB

This combination allows a crane with 2 completely reduced working areas and a SHB system with
two different limits.

Therefore the additional board of Paltronic 50 is necessary.

The load limit 1 of “slewing 1” (3) is active, if:

 Proximity switch B13 and/or B14 are on the bracket (no signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 gets a signal (12/24V), (input D is not relevant in this case)

The load limit 2 of “slewing 1” (4) is active, if:

 Proximity switch B13 and/or B14 are on the bracket (no signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 gets no signal (0V)
 The value of limit 4 has to be lower than the value of limit 5 otherwise 5 is valid!! (4 = 0V)
 The value of limit 4 has to be lower than the value of limit 6 otherwise 6 is valid!! (4 = 24V)

The load limit 1 of “slewing 2” (6) is active, if:

 Proximity switch B13 and B14 are not on the bracket (signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 4 gets 12/24V and
 input 5 gets no signal (0V)

The load limit 2 of “slewing 2” (5) is active, if:

 Proximity switch B13 and B14 are not on the bracket (signal)
 “Slewing1” is activated in the PALDIAG software and
 “Slewing2” is activated in the PALDIAG software and
 input 5 and 4 get 12/24V

2 4 Setting
1 6
5 1 Nominal load = value nominal load
2 HPLS = value HPLS (if installed)
3 Slewing 1, LL 1 = higher value SHB
4 Slewing 1, LL 2 = lower value SHB
5 Slewing 2, LL 2 = lower value reduced limit
6 Slewing 2, LL 1 = higher value reduced limit

Attention
A logical combination between slewing 2 and SHBUB or SHB07 is not possible.
For questions to complex setting requirements contact PALFINGER service.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
4.5 Order option IS001

With the order option IS001, P50 V4.2 without encoder gets the high stand limitation system with a
bracket on the column.
The additional board is necessary for the wiring.

Us
ed
inp
uts
1 High stand platform switch – left slew limit
2 High stand platform switch – right slew limit
3 Switch for high stand platform active

4.5-1 Logic of the system

If the high stand platform system (IS001) is active in Paltronic, the following logic happens:
 The switch 3 feels, if the platform is “active“. This means that the operator works from the
platform and stands on it.
 The bracket (which has to be in the area of the high stand platform) is defined by the two
switches 1 and 2. If the crane moves into the high stand area, the slewing movement stops. It
is only possible to move back out of the area.
 Paltronic shows the code 81.01.
 With the help of an additional switch (not part of the factory delivery) it is theoretically
possible to integrate the main boom angle into this system. This makes it possible, that the
crane can go over the high stand platform if the main boom angle is above the adjusted
angle.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5. Load limits and working areas – version with encoder
Paltronic 4.0 with encoder allows the use of additional load limits, which are predefined in the system
with certain options.
All limits have to be programmed with the software Paldiag.NET; the overload limits (load value) as
well as the limitation angles have to be adjusted properly.

5.1 Available load limits

Paltronic 4.2 uses the following basic concept:

0°
Nominal
HPLS
A1 A4
C2 C1 SW2

SW1
1

B2 B1
+90° -90°
SW3

C3 C4
A2 A3

+180°
 Nominal, HPLS
These limits contain adjustable load values, which define the limits for nominal load, HPLS
load, and negative load and reduced load on the crane and the fly jib. See chapter 5.2 and 4.1.

 SW1
The two load limits of ”slewing 1“ allow the settings SHB01, SHBUB, SHB05 and SHB07,
depending on the adjustment. They are all valid between the angles B1 and B2.
See chapter 5.3.

 SW2
The two load limits of “slewing 2” enable the integrated stabilizer control system ”ISC”. They
are valid between the angles A1 and A2 (left) as well as between the angles A3 and A4 (right).
The load limits are equal on both sides, the angles are free programmable. See chapter 5.4.

 SW3
The two load limits of “slewing 3“ are valid, if the stabilizers are not put down correctly.
The respective angle settings are C1-C2 and C3-C4 or from C2-C3 and C4-C1.
The load limits are equal on both sides, the angles are free programmable. See chapter 5.4.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
General logic rules of P50 load limits
 If more than one load limit is active at the same time, the lower value is used in Paltronic to
switch off.
 In this case, the system locks all movements witch increase the lifting moment or decrease the
stability.
 Paltronic shows an error code to indicate the reason for the overload situation.

5.2 Nominal load, HPLS last, negative load limits

These limits work the same way as on the system 4.0 without encoder. See chapter 4.1.

5.3 Load limit slewing 1

The load limits of the area “slewing 1” are used to control the derating system “SHB“.
Generally, SHB allows 4 different systems, which can be selected via the software Paldiag.NET:

 SHB01 Derating system with one reduced load limit.

 SHBUB SHB01 with override switch marked with the sticker “SHBUB“
 SHB05 SHB with two different limits, operated with the switch “SHB05“
 SHB07 Combination of SHBUB and SHB05, using both signals

The logic is exactly the same as on the version without encoder, see therefore chapter 4.2 and 4.3.
The difference to the version without encoder is the definition of the derated area.
Instead of using a bracket and two roller switches, the derated area has to be programmed via
Paldiag.NET at this version.

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 TRAINING
M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.4 Integrated Stability Control System ISC

The ISC system monitors the outrigger and stabilizers positions and controls the crane lifting capacity
according to the stability condition of the vehicle.
Paltronic uses additional load limits to derate the crane capacity accordingly.

5.4-1 Position monitor

The system checks the position of outriggers and stabilizers at the moment when shifting into crane
operating mode and controls the crane lifting capacity according to this information (it freezes the
condition for the complete crane working time).
The position switches have to be wired into the CAN input box 3 (see chapter 3.6).
The following rules are valid:
 Each stabilizer is recorded separately, if more than 4 are used, they have to be wired in
series to the crane or additional stabilizers.
 Depending on the crane type, either one or two positions for the outriggers are monitored
(half and fully out).
 If the crane has additional stabilizers, the outrigger position signal of the crane and the
additional stabilizers is wired in series so that only one position signal per crane side is given
to Paltronic.

The crane and stabilizer positions are shown on a LED display on the crane, called the position
monitor. This display indirectly informs the operator about the crane lifting performance by showing, if
all stabilizers are put in the correct position.
Technically, the monitor is not linked to the CAN bus of Paltronic.
For the correct wiring, see chapter 5.4-4.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.4-2 Stabilizer conditions

A) Stabilizers not used

 As long as not all stabilizers are used, the system

reduces the crane capacity to a very low limit.
 The respective load limits are adjusted under
”slewing 3“ in Paltronic.

B) Vehicle side supported with outriggers retracted

 All stabilizers must be used.

 One or more outriggers on one vehicle side are
retracted or not extend far enough to reach the first
position switch.
 Load limit 1 of “slewing 2” is valid.

C) Vehicle side supported with outriggers half extended

 All stabilizers must be used.

 All outriggers on one vehicle side are at least half
extended.
 Load limit 2 of “slewing 2” is valid.

D) Vehicle side supported with outriggers completely extended

 All stabilizers must be used.

 All outriggers on one vehicle side are completely
extended.
 Nominal or HPLS load is valid.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.4-3 Stabilizer wiring – additional board

To guarantee a correct operating of the ISC system it is absolutely necessary to wire all stabilizer
switches accordingly to the real position on the truck.
Because of the fact, that this position depends on the installation, an additional electric board has
been added to the junction box to make the connection easy.

Legend
The plug positions must be exactly like the real
position on the truck!

Plug for right front stabilizer

1 Right front outrigger half extended
2 Right front outrigger fully extended
3 Right front stabilizer in correct position

Plug for left front stabilizer

4 Left front outrigger half extended
5 Left front outrigger fully extended
6 Left front stabilizer in correct position

Plug for right rear stabilizer

7 Right rear outrigger half extended
8 Right rear outrigger fully extended
9 Right rear stabilizer in correct position

Plug for left rear stabilizer

10 Left rear outrigger half extended
11 Left rear outrigger fully extended
12 Left rear stabilizer in correct position

ATTENTION: If the crane has no additional stabilizer system, the respective plugs are nut used
(no jumpers are necessary). It is eventually necessary to correct the factory setting
if the crane has been turned 180° or rear installed.

5.4-4 Wiring of position monitor

The position monitor contains 2 plugs, which are wired as shown below.

Legend
Pin 1-12 are wired like the
additional board, see above.
G Minus (only once)
R right front/rear stabilizer
L left front/rear stabilizer

The upper plug has to be used for the

front stabilizer system, the lower one
for the rear one.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.4-5 Logic of load limits with ISC

0°
Nominal
HPLS
A1 A4
C2 C1 SW2

SW1
1

B2 B1
+90° -90°
SW3

C3 C4
A2 A3

+180°
Slewing 3, load limit 1 Is valid on both sides, if not all stabilizers are used. The value has
to be lower than the load limits of slewing 2 or slewing 1.

Slewing 3, load limit 2 Is valid within the slewing angles C2-C3 and C4-C1, if not all
stabilizers are used. The value has to be lower than the load limits
of slewing 2 or slewing 1.

Slewing 2, load limit 1 Is valid within the slewing angles A1-A2 and A3-A4, if the stabilizers
are used but the outriggers are not extended.

Slewing 2, load limit 2 Is valid within the slewing angles A1-A2 and A3-A4, if the stabilizers
are used and the outriggers are more than half but not fully
extended.

Slewing 1, load limit 1 Is valid within the slewing angles B1-B2, if the SHB system is
active. The input SHB05 must have a signal; SHBUB must not
have a signal.

Slewing 1, load limit 2 Is valid within the slewing angles B1-B2, if SHB05 or SHB07 is
activated in Paltronic. The inputs SHB05 and SHBUB must not
have a signal. This load limit requires the additional board for P50,
which is part of the order code SHB07.

In all other cases, the nominal or HPLS load limit is valid.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.5 High stand limitation system IS001, IS002

P50 version 4.0 offers the possibility to monitor two high stand platform areas.
These two areas can be activated separately with the software Paldiag.NET.
The areas are active, when the input gets no signal.

Used inputs
2 Input high stand 2 active
3 Input high stand 1 active

 The high stand areas are free programmable via the Paldiag.NET software. Therefore the angles
D1-D2 and (if applicable) D3-D4 have to be defined.
 Furthermore it is possible to include a certain boom position (main boom angle) into the logic. This
can be done by using a switch on the main boom.
 Generally, two areas can be defined. They can be used to protect a high stand platform as well as
other operating areas (for example the truck cabin).
 Since P50 V4.2 it is possible to define the locked overload function for each high stand platform
separately.

D4 D3
D1 D4 1
D1

D2
D2 D3

Example 1 Example 2
High stand platform on both sides High stand platform and cabin protection

 Overload code for “area 1 locked”: 81.01

 Overload code for “area 2 locked”: 81.11

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
5.6 Execution EN 280

If a crane is built according to the EN 280 guidelines, the logic of the ISC system has to be modified
respectively.

5.6-1 Wiring of the system

To be able to make this system, the following things must bet true:
 The workman basket is activated in Paltronic (Paldiag.NET software)
 The logic for EN 280 is activated in Paltronic (Paldiag.NET, workman basket window)
 The input signal for EN280 has to be wired up correctly; this is an input on the additional
board
 The crane must have the ISC system

Used input
1 Input for “workman basket mounted“; the
signal comes from the relay K264/1
(only possible with encoder version !!)

5.6-2 Logic of the system

Operating the crane without workman basket

 If the basket is not mounted, a signal comes from the relay K264/1 to the input 1. In this
condition, the ISC system and all other crane functions work as usual.
Operating the crane with workman basket
 When the basket is mounted, input 1 has no signal. In this condition, Paltronic changes the
logic to the EN280 rules, which state:
o The crane stabilizer system must be used completely, so that all outriggers are fully
extended and all stabilizers are used. Otherwise the stability of the vehicle is not
defined correctly.
o If the crane stabilizers are not used completely when shifting to crane mode with the
basket mounted, Paltronic shows the overload code 03.06. All load moment
increasing movements are locked in this case.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
6. Paltronic 50 special functions

6.1 Active oscillation suppression system AOS

6.1-1 Description

The purpose of the Active Oscillation System (AOS) is to minimize vertical load shocks.
To make this possible, Paltronic permanently reads out the pressure of the main lifting cylinder and
analysis it for quick pressure changes.
If such changes appear, Paltronic calculates and creates a counter signal to the control valve to
reduce the load shock.
The AOS can be switched on and off via the RRC system.
The system is only available on cranes with Danfoss control valve and RRC system.

P
Druck des Zylinders
in
über Sensoren
S
Signal der FFST über
in
Datenbus

S
Schockfreies
out
Steuersignal

6.1-2 Function and logic

To be able to use AOS, an additional electronic board (EEA-3019) has to be added into the spool
position box 1. This additional AOS board has an output for the operating signal to the main boom.
So the crane main boom function is not controlled from the RRC anymore but from the Paltronic 50
system.
AOS only works, when the crane is operated e.g. a control signal from the transmitter is given.

Emergency cut-off delay

 The setting of the “AOS delay” (normally 3s) allows the system to react against load shocks,
also after the control levers have been brought to the neutral position.
Manual AOS
 When pressing the function „AOS - manual“, the emergency cut off valve gets power manually.
It is therefore possible for AOS to work also if no control signal is given from the transmitter.
This could be used for example while unloading a concrete bulb to avoid a lifting movement of
the crane due to the unloading of the load.

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

6.2 Boom angle monitoring system (STEIL1, STEIL2)

6.2-1 Description

The system is a warning system, which informs the operator when reaching a boom angle of 60° by a
flashing light. At an angle of 70° a warning horn (overload horn H5) sounds off and all lifting
movements get blocked.

By pressing the OLP button for 0.5s (warning horn H6 gives a signal), the operator can release all
lifting movements again and continue to move in a steeper boom angle.

The reason for this system is to warn to operator that the crane is in a steep working area. In this
angle, the operator has to move the load carefully and must not overload the crane at all.

The system is used in two different ways, depending on crane model and options:

STEIL1
 The boom position is monitored by mercury switches on the crane and on the fly jib extension
booms. If one of the above mentioned switches reaches 60° or 70°, the system reacts as
explained above.
 This system is used on all cranes with more than 6 extension booms, with or without fly jib.

STEIL2
 The boom position is monitored by mercury switches on the crane and on the fly jib extension
booms. As long as the fly jib position is below horizontal, the crane boom angle does not start
off the warning system. If the fly jib position is above horizontal, the STEIL2 system works like
the STEIL1 system.
 Used on all cranes with less than 6 extension booms but with fly jib or preparation for fly jib.

6.2-2 Function and logic

An additional pendulum switch (mercury switch) is mounted on the crane outer boom (B340) and on
the fly jib knuckle boom (B341).

These switches are different to the normally used pendulum switches (B1, B301) as they are able to
give two signals for 60° and 70°. The switches are filled with a black filling material.

Also the pendulum switch for the horizontal level has been changed; it is now able to monitor an area
of 242° instead of the original 180°. This is necessary to make sure, that the STEIL system does not
give a warning when folding the crane.

Area 1: From 0° to 60°

Area 2: From 60° to 70°

Pendulum switch B340 resp. B341

Area 3: Higher than 70°

Area 4: From 0° to -242°

Pendulum switch B1 resp. B301

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
6.2-3 Overload signal

When the STEIL system reaches the switch off pint (70°), the crane switches to overload. Paltronic
comes up with code 32.00.

Therefore Paltronic uses input 6 of the additional board, which is normally used for overload on manual
extension booms.

The locking functions are programmable. For the STEIL system, all lifting functions are locked in
overload (main boom, outer boom and fly jib knuckle boom lifting).

6.2-4 Logic and switches

The following switches and relays are necessary for the system:

K1 Overrides the complete warning system as soon as the crane knuckle boom (STEIL1,
STEIL2) is below horizontal level to allow a correct folding of the crane.
Bypasses the complete warning system as soon as the fly jib knuckle boom (STEIL2)
Is below horizontal level.

K301 Only overrides the warning system of the fly jib to allow the folding of the fly jib.

K340 Gives a warning signal to the flash light as soon as the crane boom angle reaches 60°.

K342 Gives a warning signal to the flash light as soon as the fly jib boom angle reaches 60°.

ZK341 Gives a signal to Paltronic 50 at a crane boom position of 70° (with short delay) to get the
system to overload.
Code 32.00 is shown at this time, the relay K341 is also used in this line.

ZK343 Gives a signal to Paltronic 50 at a fly jib boom position of 70° (with short delay) to get the
system to overload.
Code 32.00 is shown at this time, the relay K343 is also used in this line.

K6 Is activated when pressing the OLP button. The system enables a self holding function via
Relay K345 which allows moving the crane on into steeper angles (positive signal to P50

B1 Pendulum switch with 242° range for crane outer boom in horizontal level, orange filling.

B301 Pendulum switch with 242° range for fly jib outer boom in horizontal level, orange filling.

B340 Switch for crane outer boom in 60° and 70° position, black filling

B341 Switch for fly jib outer boom in 60° and 70° position, black filling

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6

6.3 Dual power system DPS, DPS plus

6.3-1 Description

The Palfinger Dual Power System (DPS) or the Dual Power System Plus (DPS plus) is only possible
at certain crane models in combination with fly jib.
DPS increases the lifting capacity of the fly jib as long as the last crane extension boom is completely
retracted. Therefore a roller switch is necessary on the crane extension boom system to feel the last
boom.
 This switch B238 feels, if the last boom is retracted completely or not.
 If it is completely retracted (B238 has signal in this case), the load limits of the fly jib are
available.
 If B238 has no signal (the last extension boom is extended), the fly jib will be reduced to the
value of the so called „reduced load limit on fly jib“. The load limits are depending on the
static capacity of the crane boom(s).
 The reason for this reduction is the static stress in the crane extension boom system.

6.3-2 Wiring and adjustment

The switch B238 has to be wired into the fly jib spool position feeler box (address 52, refer to chapter
3.5). Due to the remote position of the switch, a relatively complicated wiring is necessary.
If activated in Paldiag.NET, the control of the load limits depends on this input. To activate the system
in Paldiag.NET, level 1 is necessary (Palfinger factory level).
 If the input has a signal, the load limits 1 and 2 (nominal and HPLS) can be used.
 If the input has no signal, the load limit 3 and 4 (the reduced limits) are active.

Legend: Input 10 is prepared for the switch B238

(refer to chapter 3.5)

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
6.3-3 Lifting force with DPS

The DPS system has been designed for the Paltronic 50 Version 4.0, which only allowed one reduced
load limit for the fly jib.
Therefore there is no HPLS available in the reduced area, so the fly jib can only lift the nominal load
when in DPS mode.
The fly jib lifting force with DPS at fully extended crane boom position is therefore lower than the
lifting force on cranes without DPS at the same position (refer to the below example: 780 kg (1720
lbs) versus 890 kg (1962 lbs)).

Example DPS
 Das Fly-Jib hat ohne DPS bei voll ausgefahrenem Kran 890 kg (1962 lbs) Hubkraft, mit DPS
nur mehr 780 kg (1720 lbs), da im DPS Bereich kein HPLS möglich ist.

6.3-4 Lifting force with DPS plus

The DPS plus system has been designed for the Paltronic 50 Version 4.2, which allows two different
load limits in reduced area.
It is therefore also possible to have a HPLS function in the DPS plus area.
The fly jib lifting capacity at fully extended crane boom system with DPS is therefore equal to the
lifting capacity without DPS.

Example DPS plus

 The fly jib has a lifting capacity at fully extended crane boom position of 1080 kg (2381 lbs),
with or without DPS plus installed.

without DPS DPS plus

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M2-1 Paltronic 50 V4.2 / V4.4 / V4.6
7. Load limits with Fly-Jib

7.1 Available load limits

Paltronic 50 Version 4.2 is designed to have the following load limits for fly jib:

 Nominal
 HPLS
 DPS
 DPS plus
 Negative load limit

7.2 Logic of load limits

7.2-1 Fly-Jib Nominal

This load limit is always active, if no other fly jib load limit is active.
Overload code 30.01

7.2-2 Fly-Jib HPLS

The HPLS load limit is activated/deactivated with the crane HPLS load limit, if HPLS for fly jib is
available (activated in Palidag.NET). Overload code 30.02

Generally it is possible to operate a HPLS crane with a fly jib without HPLS, but this is not sold from
factory (anymore).

7.2-3 Load limit DPS

The DPS load limit is activated on all models with DPS or DPS plus.

On cranes with DPS, the DPS load limit is active as soon as last crane extension boom gets
extended (B238 does not give a signal anymore). Overload code 30.09

On cranes with DPS plus, the DPS load limit is active as soon as last crane extension boom gets
extended (B238 does not give a signal anymore) and HPLS is switched off.

7.2-4 Load limit DPS plus

The DPS plus load limit is only activated on cranes with DPS plus system.

The DPS plus load limit is active as soon as last crane extension boom gets extended (B238 does
not give a signal anymore) and HPLS is switched on. Overload code 30.10

7.2-5 Negative load limit Fly-Jib

With the help of the negative load limit on the fly jib it is possible to reduce the lowering force of the fly
jib to a certain capacity. This is mainly used to avoid “digging” with the fly jib.
P50 shifts to overload (if activated) as soon as the lowering force reaches the programmed value.
Overload code: 30.05

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